Operating Instructions Sonnenschein Rail

Instructions for use fr 6–7
nl 8–9
Gebruiksaanwijzing es 10–11
Instrukcja eksploatacji pl 12–13
cs 14–15
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4V 6V 8V 10V 12V
1,8 3,65,47,2 9 10,8
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Operating Instructions for
Valve-Regulated Cells/Block
Batteries for Rail Vehicles
Series PzV, EPzV-BS, Sonnenschein Rail
Nominal data
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Battery type
Nominal capacity
CN=C5
Nominal voltage UN
Final discharge voltage
Uf
Discharge current
I N =I 5
Nominal temperature TN
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see type plate
see type plate
2,0 V x number of cells
1,70 V / cell at 30 °C
C5 / 5 h
30° C
Observe these Instructions and keep them located near the battery for future
reference.
Work on the battery should be carried out by qualified personnel only.
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Do not smoke.
Do not use any naked flame or other sources of ignition.
Risk of explosion and fire.
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While working on batteries wear protective eye-glasses and clothing.
Observe the accident prevention rules as well as EN 50272-2,
EN 50110-1.
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Any acid splashes on the skin or in the eyes must be flushed with plenty of
clean water immediately. Then seek for medical assistance. Spillages on
clothing should be rinsed out with water!
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Warning: Risk of fire, explosion or burns. Do not disassemble, heat above
60 °C, or incinerate. Avoid short circuits.
Avoid electrostatic charges and discharges/sparks!
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Electrolyte is very corrosive. In normal working conditions the contact with the
electolyte is impossible. If the cell/block container is damaged do not touch
the exposed electrolyte because it is corrosive.
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Blocks/cells are very heavy! Make sure they are installed securely! Only use
suitable means of transport!
Block/cell containers are sensitive to mechanical damage.
Handle with care!
Do not lift or pull up blocks/cells on the poles.
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Caution! Metal parts of the battery are always alive, therefore do not place
items or tools on the battery.
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Keep children away from batteries.
Non-compliance with operating instructions, installations or repairs made with other than
original accessories and spare parts or with accessories and spare parts not recommended
by the battery manufacturer or repairs made without authorization (e. g. opening of valves)
render the warranty void.
Spent batteries have to be collected and recycled separately from normal household
wastes (EWC 160601). The handling of spent batteries is described in the EU Battery
Directive (2006/66/EC) and their national transitions (UK: HS Regulation 1994 No. 232,
Ireland: Statory Instrument No. 73/2000). Contact your supplier to agree upon the
recollection and recycling of your spent batteries or contact a local and authorized
Waste Management Company.
Pb
PzV-cells and Sonnenschein RAIL-batteries are
valve-regulated cells/block batteries with electrolyte fixed in gel. Replenishing with water is
prohibited over the whole period of use. Overpressure valves which are destroyed when
opened are used as sealing plugs. During use,
the same safety requirements are made of the
valve-regulated batteries as on batteries with
liquid electrolyte in order to avoid hazards
through electric shock, explosion of the electrolytic charging gases and corrosive electrolytes
in the event of the cell structure becoming
damaged.
1. Start-up procedure
The battery must be checked to ensure it is in
perfect mechanical working order. The battery
end conductor must be connected safely and
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with the correct polarity. Otherwise the battery,
vehicle or charger could be destroyed. The battery must be recharged in accordance with section 2.2.
Tightening torque for pole screws on the
end conductors and connectors:
PzV, EPzV-BS Sonnenschein RAIL
F-M10 23 ± 1 Nm
17 ± 1 Nm
A-Pole
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8 ± 1 Nm
G-M6
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6 ± 1 Nm
M8*
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15 ± 1 Nm
M10*/M12*
30 ± 1 Nm
Wingnut
Tighten by hand
* Pole clamps with stud bolts must be countered
accordingly
2.Operation
EN 50272-2 “Safety requirements for batteries
and battery systems - Part 2: Stationary
batteries” (or equivalent IEC 62485-2) and EN
50547 “Railway applications - Batteries for auxiliary power supply systems” are applicable for the
operation of lead batteries for rail vehicles.
Vent plugs on the battery must not be sealed or
covered. Electrical connections (e.g. plugs) must
only be made or interrupted in the open circuit
condition.
2.1Discharging
The discharge current associated final discharge
voltage must not be undershot. Discharged batteries must be char­ged immediately and may not
be left in a discharged state. This also applies to
partially discharged batteries.
2.2 Charging (including externally)
Only direct current (DC) may be used for charging. The charging methods in accordance with
DIN 41773 (IU-curve, I-const: ± 2%, U-const:
±1%) may only be used in the modification
approved by the battery manufacturer. For this
reason, only chargers approved by the battery
manufacturer may be used. Connection only to
the assigned charger approved for the battery
size in order to avoid excess load on the electric
cables and contacts as well as extreme gassing.
Valve-regulated cells/block batteries are lowgassing but not gassing-free. During charging,
care must be taken that the charging gases can
escape properly (ventilation acc. to EN 50272-2
or IEC 62485-2).
External charging:
Lids and covers of battery compartments must
be opened or removed if necessary. The battery
has to be connected with the correct polarity
(positive to positive, negative to negative) to the
charger switched off. Then switch on the charger. In the case of a complete full charge, the
temperature rises in the battery by about 10 K.
Therefore, the charge should be initiated only
when the temperature is below 40 °C. The temperature should be at least 15 °C before charging, otherwise no proper charge is reached.
General:
Are the temperatures consistently higher than
35 °C or lower than 15 °C a temperature-regulated
constant voltage of the battery charger is
required. This correction factor of -0.004 V per
cell per K must be applied. As a basis the limits
of max. 2.40 V/cell respectively min. 2.23 V/cell
apply. For very low temperatures below freezing
for several months specially tailored charging
method with higher limits can be defined by the
battery manufacturer.
2.3 Buffer operation
(typical for rail vehicles)
With buffer operation, the DC source is not able
to supply the required load current at all times.
The DC source is either not available at all for
short periods or it does not supply the required
amount of current. During this time, the battery
supplies the current. The battery is not fully
charged at all times. Therefore, the charging
voltage is set based on 20 °C consumerdependent from 2.30 to 2.38 V/cell.
2.4 Retaining the fully charged state
(float charge)
This operating mode is rare with rail vehicles but
it can be used for maintenance purposes or storage, for example. Chargers with specifications in
accordance with DIN 41773 should be used. The
float charge voltage is 2.30 V/C at 20°C.
2.5 Charging currents, superimposed
alternating currents
The Charging currents are not limited during
buffer operation or recharging up to float charge
voltage (guide values: 10 to 35 A/100 Ah C5).
Regarding superimposed alternating currents
the values acc. to EN 50272-2 must not be
exceeded.
2.6 Equalizing charge
Equalizing charges are used to safeguard the
service life and maintain the capacity. Equalizing
charges are carried out in addition to a normal
charge. An equalizing charge is required after
deep-discharge and/or inadequate charges. It
can be carried-out with constant voltage of max.
2.40 V/cell with or without limiting the charging
current (typical values 10 to 35 A/100 Ah C5) up
to 48 hours.
The charging has to be interrupted if the max.
temperature of 45 °C is exceeded. Or the charge
mode has to be switched to float charge operation
temporarily to allow the temperature to drop.
2.7 Temperature
The technical specifications of these batteries
apply for a nominal temperature 30 °C. Higher
annual average temperatures will shorten the
service life. Lower temperatures reduce the
available capacity. Continuous operation at temperatures above 45 °C should be avoided if possible.
55 °C is the threshold temperature and is not
acceptable as a permanent recommended operating temperature.
2.8Electrolyte
The electrolyte is sulphuric acid which is fixed in
a gel. The density of the electrolyte cannot be
measured.
3. Battery maintenance and control
No water refill!
The measurement data have to be recorded.
They are the basis for possible warranty claims.
Every six months and every year:
Carry out a visual inspection for contamination
and mechanical damage.
• Check cable connections
• Battery surface temperature
Electrical quick check:
At the fully charged battery before, during and at
the end of the discharge measure and record:
• Overall battery voltage
• All carrier voltages/block voltages
• Where individual cells are used: all cell
voltages
The measurements must be carried out with the
rectifier switched off and the the load switched
on.
The test should be carried out over the time that
can be assigned to the discharge current if possible. The test statements are less reliable with
shorter discharge times. The load should be kept
as constant as possible.
Test criteria:
Cancellation if the overall voltage = number of
cells x Uf [V/c] or the weakest cell has reached
its limit.
The weakest cell may drop to Umin = Final discharge voltage Uf [V/c] - 0.2 V.
With block batteries tolerance is assumed with
an even statistical distribution.
Thus the tolerance of the blocks = Tolerance of
the cells x √ number of cells in the block.
Reduction values using the example of an average end-of-discharge voltage Uf = 1.8 V/C:
6. Storage and taking out of operation
If batteries are put out of operation for longer
periods, they must be stored fully charged in a
dry, frost-free room. To ensure the battery is
ready for operation, the following charging treatment can be carried out:
1.Full charge in accordance with section 2.6
after max. 12 month at max. 20 °C. At
average ambient temperatures of more than
20 °C shorter intervals are necessary. If
a load e.g. measuring or inspection equipment is connected, full charge may be
necessary every 14 days.
2. Float charge accordance to 2.4.
The storage time must be taken into account for
the service life.
7.Malfunctions
If faults are found in the battery or charger, the
customer service department should be called
immediately. Measured data in accordance with
section 3 make it easier to find and eliminate the
fault.
Cell/block/carrier* 2V 4V 6V 8V 10V12V
Mean Uf [V]
1.8 3.65.47.2 9 10.8
Tolerance [V]
- 0.2 -0.28-0.35-0.40-0.45-0.49
1.6
3.32
5.05
6.80
8.55
10.31
Umin [V]
* The voltages of the individual cells shoud be measured if possible, since these values are more meaningful.
More precise details on test procedures and
evaluation can be found in IEC 60896-21 (chapter “6.11 Discharge capacity”).
A service contract with ourselves makes it easier
to recognise faults in good time.
4.Care
The battery must always be kept clean and dry
to avoid leakage currents. Cleaning is to be performed in accordance with the ZVEI leaflet
“Cleaning batteries”. Any liquid in the battery
trough must be extracted and disposed of in line
with regulations.
Damage to the tray insulation must be repaired
following cleaning of the damaged spots in order
to guarantee insulation values in accordance
with EN 50272-3 and avoid tray corrosion.
The insulation resistance of the battery should
not fall below 50 Ω per Volt nominal voltage. In
the case of batteries up to 20 V nominal voltage
the minimum value is 1000 Ω.
8.Transport
Cells and block batteries must be transported in
an upright position to prevent electrolyte escaping. Cells and block batteries which are not damaged in any way, or maintenance-free cells and
block batteries with immobilized electrolyte are
not defined as dangerous goods according to
the ordinance on the transport of hazardous
goods by road (ADR) or rail (RID). They must be
secured against short-circuit, slipping, falling
over or damage. Block batteries can be stacked
in a suitable way, secured on pallets (ADR or
RID, special rule 598). Pallets must not be
stacked. No hazardous traces of acid may be on
the outside of the packaging units. Block batteries and cells which are leaking or damaged must
be packed and transported as dangerous goods
of class 8, UN-no. 2794.
5. Capacity test
If capacity is monitored within the tests listed
under section 3, the five-hour capacity C5 (1.7
V/c, 30 °C) should preferably be tested. Procedure
should be in accordance with IEC 60 896-21.
Here, chapter “6.11 Discharge capacity” concerns
the preparation, implementation and evaluation
of a capacity test.
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Pb
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fr
4V 6V 8V 10V 12V
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fr
7
Batterijtype
Nominale capaciteit
CN=C5
Nominale spanning UN
Uiteindelijke ontladingsspanning US
Ontladingsstroom
I N =I 5
Nominale temperatuur TN
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Pb
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Cel/blok/drager* 2V 4V 6V 8V 10V12V
Gemiddelde Uf [V]1,8 3,6 5,47,2 9 10,8
Tolerantie [V]
- 0,2 -0,28-0,35-0,40-0,45-0,49
nl
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10
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4V
6V
8V
Uf media [V]
1,8
3,6
5,4
7,2
10V
Tolerancia [V]
- 0,2-0,28 -0,35 -0,40 -0,45 -0,49
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12V
10,8
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Dane nominalne
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4V
8V
10V 12V
1,8 3,65,47,2 9 10,8
- 0,2 -0,28-0,35-0,40-0,45-0,49
pl
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Technologies
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Dětem zamezte kontakt s akumulátory.
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cz
4V
8V
10V
12V
1,83,6 5,4 7,2 9 10,8
- 0,2-0,28 -0,35 -0,40 -0,45 -0,49
10,31
cz
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56130002 1,0 IX.11
NXSR8OEPDF00814 · Druckhaus Bechstein · Printed in Germany · Subject to change
Competence Center:
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Tel.: +49 (0) 60 42 / 81 343
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Fax: +49 (0) 55 24 / 82 480
Stand: Januar 2015
www.gnb.com
T
Technologies